A little rust repair

[dmcummins]

After seeing some of the restorations going on here I decieded to take a look at repairing my rocker on my roller. The aftermarket a/c lines were run through the rocker so I pulled them out and took a look to see how bad things were.

[frogger]

Ouch @$&^?#%!!!

[dmcummins]

Thankfully the inner rocker looked ok so I just hit everything with Por 15.

[dmcummins]

I layed over the replacement piece after I cut it down to a larger size and cut thru both at the same time and then tacked it in place.


It really was not that difficult. Wire welders are sure handy.

[Porsche-O-Phile]

Nice work. How does POR-15 hold up so close to welding work? I'd be a bit afraid of the stuff igniting or whatever, but it looks like you had good luck.

[dmcummins]

I didn't think about the POR-15 burning. I just had some sitting around and thought it wouldn't hurt to dab some in there. I still have the holes at each end where the a/c lines were run to shoot something in for rust prevention.

[john70t]

There are a couple of rubber plugs in the rocker where a flexible sprayer can be fed for spraying the backside of the rocker and inside the 1/4 panel.
I used a homemade mix of waxoyl mixed with a can of rust-mort sprayed through a deck sprayer, but there are probably easier-sprayed high-tech chemicals with better protection available.

[john70t]

One thing about POR-15 is that it isn't infailable.
As a test, I painted the chassis rails on a van(no acid or other prep and with some left-over stuff) and within a year there was spot rust showing through. I've also gotten some new cans with a very lumpy consistency, as if they had been frozen.

[Zeke]

The POR just burns off like anything else. It doesn't really catch fire, just makes a mess. You really don't want it directly behind your welds anyway. That's a job for later as John does it.

Weld thru primer is OK, but it makes welding tougher and contaminates the welds. Not such a big deal when plug welding, but try to run a perfect bead and you're gonna see the crap in the weld. Better to coat these areas post welding. You can do it if you want to, you just have to have some thing to insert the material into the cavity and spread it around. I blow the POR or whatever I'm using into all seams with air. I'll even fill a pea shooter with paint, inset it into the hole and then discharge it with a blast of air. Cover up.

[frogger]

Originally Posted by milt

I'll even fill a pea shooter with paint, inset it into the hole and then discharge it with a blast of air. Cover up.

milt, what's a pea shooter? Thanks.

[berettafan]

welding on the opposite side of a POR coated piece of metal will cause the POR to 'release' from the surface. i assume the same can be caused by sparks from welding nearby though not nearly so extensively.

and i agree (now that i have a small amount of experience) that weld thru primer adds to the challenge at sheet metal heat levels.

[dmcummins]

Well as I said I still have the holes from the a/c lines so it shouldn't be that hard to shoot something in their before I close it up. maybe I should just screw a plate over the hole that I could remove from time to time and reapply some rust prevenative.